Northern Lights M175C2 Operator's Manual

OPERATOR’S

OPERATOR’S

MANUAL

MANUAL

OM175C2

OM175C2

For Model:

M175C2

— CALIFORNIA —

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

Northern Lights

4420 14th Avenue N.W.
Seattle, WA 98107
Tel: [phone]
Fax: [phone]

Copyright ©2005 Alaska Diesel Electric, Inc.
All rights reserved. Northern Lights™, and
the Northern Lights logo are trademarks of
Alaska Diesel Electric, Inc.

Printed in U.S.A.
PART NO.: OM175C2 04/05

OPERATOR'S MANUAL

Read this operator's manual thoroughly before starting to operate your equipment.

This manual contains information you will need to run and service your new unit.

Table of Contents

OM175C2 for Model

M175C2

INTRODUCTION ................................................... 2

Models Included ................................................ 2

Model Numbers................................................. 2

Serial Numbers .................................................. 2

WARRANTY ........................................................... 3

SAFETY RULES .................................................... 3

COMPONENT LOCATIONS

M175C2............................................................. 4

ENGINE & GENERATOR CONTROL PANELS

Series 1, 3 & 4 ..............................................5 - 6

OPERATING PROCEDURES

Before Starting .................................................. 7

Shutdown Procedures ...................................7 - 8

Break-In Period ................................................. 8

SERVICING SCHEDULE CHART ...................... 9

SERVICE RECORD ............................................ 10

SERVICING

Lubrication - General ...................................... 11

Checking Oil ................................................... 11

Oil Changes ..................................................... 11

Changing Oil Filter.......................................... 11

Air Filter .......................................................... 11

Valve Clearances............................................. 12

Fuels - General ................................................ 13

Fuel Filters....................................................... 13

Crankshaft Damper ......................................... 14

Bleeding the Fuel System........................ 15 - 16

Injector Service ............................................... 16

Turbocharger ................................................... 17

Turbo Boost..................................................... 17

Cooling System - General ............................... 17

Engine Coolant Specifications ................ 18 - 19

Cooling System Flushing ................................ 19

Heat Exchanger Cleaning................................ 19

Zinc Anodes .................................................... 20

Raw Water Pump ............................................ 20

Generator Ends ................................................ 20

Electrical System - General............................. 20

Booster Batteries ............................................. 21

Battery Care..................................................... 21

Winterizing / Out-of-Service........................... 21

TROUBLESHOOTING

Electrical.......................................................... 22

Engine...................................................... 22 - 24

WIRING DIAGRAMS

AC Electrical ................................................... 25

DC Electrical ........................................... 26 - 27

ON-BOARD SPARE PARTS............................. 28

Proprietary Information

This publication is the property of Alaska Diesel Electric, Inc.

It may not be reproduced in whole or in part without the written permission of Alaska Diesel Electric, Inc.

© Alaska Diesel Electric, Inc. All rights reserved. Litho U.S.A. Publication number OM175C2 04/05

OM175C2 04-05

3

Introduction

Servicing of marine engines and generator sets presents
unique problems. In many cases boats cannot be moved
to a repair facility. Marine engines cannot be compared

Failures begin with minor problems that are overlooked
and become amplified when not corrected during

routine maintenance.
to the servicing of automobiles, trucks or even farm
equipment. Failures often occur in remote areas far
from competent assistance. Marine engines are taxed
far more severely than auto or truck engines; therefore,
maintenance schedules must be adhered to more
strictly.

As operator, it is your obligation to learn about your

equipment and its proper maintenance. This is not a

comprehensive technical service manual. Nor will it

make the reader into an expert mechanic. Its aim is to

aid you in maintaining your unit properly.

Model Numbers

Model numbers give the unit's application, block model, aspiration, and RPM:

M

M - Northern Lights marine generator set

M175C2

Northern Lights® turbocharged, 1800 RPM marine diesel
generator set with a John Deere 6081 Tier II engine block,

=

two valve with high pressure common rail.

+

6 Cylinders 8.1 Liters

175

Model number

Serial Number Plates

Serial Numbers

When referencing Alaska Diesel Electric equipment by serial number, please refer only to the number
stamped on the Northern Lights® serial number plate.

OM175C2 04-05

4

Warranty

A warranty registration certificate is supplied
with your set. The extent of coverage is described
in the Limited Warranty Statement. We
recommend that you study the statement carefully.

NOTE: If the warranty is to apply, the servicing
instructions outlined in this manual must be
followed. If further information is needed, please
contact an authorized dealer or the factory..

Safety Rules

CAUTION:

You can avoid accidents by observing these safety rules. Study these rules carefully and enforce them on the job.

• Never leave engine without proper security.

• Turn the coolant tank cap slowly to relieve

pressure before removing. Add coolant only
when the engine is stopped and cool.

• Mount a fire extinguisher near engine.

• Always disconnect the battery ground strap

before making adjustments.

• Operate engines in properly ventilated areas.

• Keep trash and other objects away from engine.

• Escaping fluids under pressure can penetrate

your skin. Use a piece of cardboard or wood,
not your hands, to search for leaks.

• Avoid wearing loose clothing when working
around engines.

• Do not oil or grease engine while it is running.

• Use caution in handling fuel. Never refuel a hot

or running engine. Do not smoke while filling
fuel tank or servicing fuel system.

Accident reports show that careless use of engines causes a high percentage of accidents.

• Keep your hands, feet, hair and clothing away
from power-driven parts.

• Check for any loose electrical connections or
faulty wiring.

• Always disconnect ECU (Electronic Control
Unit) connectors and engine control system-to­vessel ground before welding. High currents or
electro-static discharge in electronic
components from welding may cause permanent
damage.

• Engines should be operated only by
knowledgeable, qualified personnel.

• Look completely around engine to make sure
that everything is clear before starting.

• Do not operate an engine that isn't in proper
working order. If an unsafe operating condition is
noted, tag the set and control panel so others will
also know about the problem.

• Provide first aid kits.

CALIFORNIA

Proposition 65 Warning:

Diesel engine exhaust and some of its constituents

are known to the State of California to cause

cancer, birth defects, and other reproductive harm.

CAUTION: This symbol is used throughout
this book to alert you to possible danger areas.
Please take special notice of these sections.

OM175C2 04-05

5

M175C2 Component Locations

Figure 1 & 2: M175C2

1. Junction Box

2. Air Cleaner

3. Secondary Fuel Filter

4. Primary Fuel Filter

5. Lube Oil Filter

6. Injection Pump

7. Coolant Fill

8. Expansion Tank

9. Heat Exchanger

10. Heat Exchanger Zincs

11. Belt Guard

12. Fuel Manifold

13. Lube Oil Drain

14. Lube Oil Fill

15. Turbocharger

16. Electronic Control Unit

17. Starter

18. Aftercooler

OM175C2 04-05

6

19. Alternator

20. Thermostat Cover

Figure 3: Series 3 Generator Control Panel

Northern Lights Control Panels

1. SHUTDOWN BYPASS SWITCH

This switch bypasses the safety shutdown feature
during the starting process.

2. ENGINE CONTROL SWITCH

To start the engine, hold this switch in the START
position until the engine is running.

NOTE: Excessive cranking of marine sets equipped
with water lift muffler systems can cause engine
damage.

After the engine starts, release the switch and it will
return to RUN position. To stop the engine, hold
the switch in the STOP position.

NOTE: The rocker switch is used on Series 1
panels only, and has a light that glows when the set
is running.

3. OIL PRESSURE GAUGE

The oil pressure gauge shows the oil pressure in the
engine lubricating system. If the pressure drops
below 15 PSI at a speed higher than idling, stop the
engine and investigate.

Figure 4: Series 1-B Generator Control Panel

Figure 5: Series 3C Generator Control Panel

4. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of
the cooling water. If the gauge registers over 200°
or drops below 140°, stop the engine and
investigate.

5. HOUR METER

Keeps track of the engine running time.

6. DC VOLTMETER

When the engine is running, it indicates the voltage
output of the alternator.

OM175C2 04-05

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Northern Lights Control Panel

Figure 6: Series 4 Generator Control Panel

1. SHUTDOWN BYPASS SWITCH

This switch bypasses the safety shutdown feature
during the starting process.

2. ENGINE CONTROL SWITCH

The control switch starts and stops the engine.

3. OIL PRESSURE GAUGE

The oil pressure gauge shows the oil pressure in the
engine lubricating system. If the pressure drops
below 15 PSI at a speed higher than idling, stop the
engine and investigate.

4. COOLANT TEMPERATURE GAUGE

Water temperature gauge shows the temperature of
the cooling water. If the gauge registers over 200°
or drops below 140°, stop the engine and investi­gate.

5. HOUR METER

Keeps track of the engine running time.

6. DC VOLTMETER

When the engine is running, it indicates the voltage
output of the alternator.

7. AC VOLTMETER

The voltmeter shows the generator output voltage,
phase to phase. If the voltage fluctuates greatly from
the normal reading, shut down the unit and investi­gate.

8. FREQUENCY METER

Indicates engine speed. The correct reading for 1800
RPM sets is 60 Hz. If meter does not indicate
correct hertz, stop and investigate.

9. AMMETER SELECTOR SWITCH

The ammeter switch is used for checking each phase
for load condition. Leave it in the ON position while
the engine is running.

10. AC AMMETER

The ammeter indicates the phase load. Check for
load unbalance. If the unbalance is greater than 30%,
have an electrician balance the load properly. This
will ensure longer generator life and better economy.

OM175C2 04-05

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Operating Procedures

BEFORE STARTING

1. Check the water level by removing the pressure
cap from the expansion tank. In order to give the
cooling water room to expand, the level should be
about 1 3/4 in. (4-5 cm) below the filler cap sealing
surface when the engine is cold. When filling with
coolant, the venting cock on top of the turbocharger
should be opened to ensure that no air pockets form
in the cooling system (see Service Point #12)

CAUTION: Use protective clothing and open
the filler cap carefully when the engine is warm
to prevent burns.

.

2. Check the oil level in the crankcase with the dipstick.
The oil level should be between the “waffled area”
and the “oo”. Never allow the level to go below the
“oo”. Always add the same viscosity of oil as is
already in the crankcase (see Service Point #1).

3. Check the fuel tank level and open any fuel valves.

4. Disengage clutch, if equipped.

5. Close the seacock, check and clean the strainer and
reopen the seacock.

6. Place the battery switch in the ON position.

NOTE: The battery switch must always be kept ON
while the engine is running. If the switch is turned
OFF while the engine is running, the battery charging

regulator could be ruined.

Operating

1. Check Gauges Often: Oil pressure must be above
29 PSI (if not above 15 PSI within 5 seconds of
starting, the engine should be stopped and the
problem should be explored.) Normal oil pressure is
50 PSI at rated load speed (1800 to 2500 RPM). The
DC voltmeter should read between 13 -14 volts (26 ­28 volts, 24 volt systems).

2. Check AC voltage and frequency meters (Series 4
Panel). If gauges deviate from normal levels, shut
down the set and investigate.

3. Check belt for good alignment.

4. Let the unit run unloaded for a three to five minute
warm-up period before applying load.

5. Do not add full electrical load until engine is at
maximum operating temperature.

Shutdown

1. Unload the generator and run for three to five
minutes for cool down period.

2. Turn the Engine Control Switch to the OFF position.

3. Close the sea cock and fuel valves, and put the
battery switch in the OFF position if the unit will be
off for an extended period.

NOTE: Do not turn the battery switch to OFF while
the engine is running.

Starting

1. While holding the Shutdown Bypass switch in the
ON position, push the Engine Control switch to the
START position

2. As soon as the engine starts, release both switches.

Do not crank the starter for more than 20 seconds.

3. If the engine fails to start the first time, be sure the
starter has stopped for at least 2 minutes before
reengaging.

NOTE: If there is a governor locked at a specific
speed on the generator set, there may not be a slow
idle function, so in that case operate the engine at
high idle for 1 to 2 minutes before adding load. If the
stand-by generator set is loaded as soon as it
reaches rated speed, this procedure would not apply.

SHUTDOWNS AND ALARMS

1. Your unit is fitted with a system to protect it from
high water temperature or low oil pressure.

a. Generator sets have shutdown systems to stop the

engine. They have no warning horns.

b. Other alarms and shutdowns are available as

optional equipment.

NOTE: Do not rely on your warning or shutdown
system to the exclusion of careful gauge monitoring.
Watching your gauges can prevent damage to the unit
and dangerous power losses.

2. Do the following when your shutdown system is
activated: (next page)

OM175C2 04-05

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